Storage battery protection by engine air intake system

ABSTRACT

Duct structure (22) is disposed in an engine compartment (10) of an automotive vehicle and comprises a main air passageway (32) that runs from an intake (34) at one end to an outlet (36) at an opposite end. A section of the length of passageway (32) is disposed to run alongside a vertical wall of the casing of a battery (24) that is toward an engine (12). Heat impinging on the duct structure is dissipated to the airflow through the passageway. Various features are integrated with the duct structure including resonators (38, 40), a deflector (48), and a battery enclosure (50) for containment of electrolyte that is accidentally spewed or leaked from the battery casing so that the liquid does not entrain with the intake airflow to the engine.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to automotive vehicles that are powered byinternal combustion engines and that have electrical systems containingstorage batteries.

2. Background Information

Lead-acid storage batteries are commonly used in electrical systems ofautomotive vehicles to provide electric energy for operating startermotors to crank engines that power the vehicles. During running of anengine, an alternator that is driven by the engine keeps the batteryrecharged through an electric regulator. It is generally desirable forthe battery to be disposed in proximity to the engine so that ohmiclosses can be minimized during cranking when current draw on the batteryis quite high. Over time, such a battery ages, and eventually reaches apoint where it is incapable of sustaining sufficient charge to serve theneeds of a vehicle.

Heat is a contributor to battery aging, and because an engine in anengine compartment can at times be a source of significant heat, variousarrangements have heretofore been proposed to shield the battery fromengine heat. It is believed that the following U.S. Patents arerepresentative of the state of the art: U.S. Pat. No. 4,126,734; U.S.Pat. No. 4,976,327; U.S. Pat. No. 5,031,712; U.S. Pat. No. 5,082,075;U.S. Pat. No. 5,215,834; U.S. Pat. No. 5,320,190; and U.S. Pat. No.5,542,489.

It is generally known to associate an engine intake system with aninternal combustion engine air intake system with a storage battery sothat the battery is shielded by heat dissipation to the intake airflow.Certain of the arrangements in the above patents utilize blowers and/orother moving parts to accomplish their objectives. It is believed thatsuch components increase the cost of a battery protection system andthat it would therefore be beneficial if meaningful battery protectioncould be accomplished without such components.

SUMMARY OF THE INVENTION

In one respect, the present invention relates to engine air intakesystems that provide storage battery protection without using devotedcomponents that have moving parts. Stated another way, the inventionrelates to air intake structures that are associated with storagebatteries in engine compartments of automotive vehicles and that performactive cooling of storage batteries by dissipating heat to engine intakeairflow, but through passive structures that do not use devotedcomponents having moving parts. It is believed that such passivestructures provide favorable cost advantages and fewer reliabilityissues in comparison to systems like those in some of the above patents.

A further aspect of the invention relates to the integration, with suchpassive structures, of certain features useful to the engines. Oneintegration feature relates to the association of one or more engineintake system resonators in thermally protective relation to a storagebattery in an engine compartment. Another integration feature relates tothe containment of electrolyte that may accidentally escapes from astorage battery due to causes such as vent spewing or casing failure.

A general aspect of the within claimed invention relates to an enginecompartment of an automotive vehicle that houses an internal combustionengine having an air intake system and that also contains an electricalsystem storage battery in spaced apart relation to the engine; ductstructure that forms a portion of the air intake system and comprises aninlet at which intake air enters and a passageway that conveys theintake air from the inlet, lengthwise through the passageway, to anoutlet; a portion of the length of the passageway being disposed incovering relation to a wall of the battery that is toward the engine;and a branch that is disposed in covering relation to another wall ofthe battery and that comprises a space that is open to the passageway,but otherwise closed.

Another general aspect relates to an engine compartment of an automotivevehicle that houses an internal combustion engine having an air intakesystem and that also contains a electrical system storage battery inspaced apart relation to the engine; duct structure that forms a portionof the air intake system and comprises an inlet at which intake airenters and a primary passageway that conveys the intake air from theinlet, lengthwise through the passageway, to an outlet; a portion of thelength of the primary passageway being disposed in covering relation toa wall of the battery that is toward the engine; and a secondarypassageway that is disposed in covering relation to another wall of thebattery and that branches from the first passageway, comprising anentrance upstream of the portion of the length of the primary passagewaythat is disposed in covering relation to a wall of the battery that istoward the engine and an exit downstream of the portion of the length ofthe primary passageway that is disposed in covering relation to a wallof the battery that is toward the engine; and in which the primarypassageway comprises a non-movable deflector wall that is disposedimmediately upstream of the entrance of the secondary passageway and iseffective at a relatively lower flow rate to cause proportion the flowthrough the two passageways such that the proportion of flow through theprimary passageway to the flow through the secondary passageway isrelatively larger than is the proportion of flow through the primarypassageway to flow through the secondary passageway when the flow rateis relatively higher.

Still another general aspect relates to an engine compartment of anautomotive vehicle that houses an internal combustion engine having anair intake system and that also contains an electrical system storagebattery in spaced apart relation to the engine; duct structure thatforms a portion of the air intake system and comprises an inlet at whichintake air enters and a passageway that conveys the intake air from theinlet, lengthwise through the passageway, to an outlet; a portion of thelength of the passageway being disposed in covering relation to anenclosure that associates with a tray on which the battery is supportedto enclose the battery; the enclosure comprising a top that covers a topof the battery and a perimeter wall extending downward from the top tothe tray in covering relation to the perimeter of the battery.

Other general and more specific aspects will been set forth in theensuing description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings that will now be briefly described are incorporated hereinto illustrate a preferred embodiment of, the invention and a best modepresently contemplated for carrying out the invention.

FIG. 1 is a top plan view, somewhat diagrammatic in nature, of a portionof an engine compartment relevant to the present invention.

FIG. 2 is a view of a portion of FIG. 1 illustrating a modified form.

FIG. 3 is a view of another modified form on an enlarged scale.

FIG. 4 is a view of still another modified form also on an enlargedscale.

FIG. 5 is a vertical cross section view through a portion of yet anothermodified form.

FIG. 6 is an enlarged view in circle 6 of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows an engine compartment 10 of an automotive vehiclecomprising an internal combustion engine 12. Engine compartment 10 is atthe front of the vehicle. A cooling module 14 that forms a portion of aliquid cooling system of engine 12 is disposed at the front of enginecompartment 10.

An air intake system 16 through which fresh air is conveyed intocombustion chambers of engine 12 is also disposed within enginecompartment 10. The illustrated air intake system 16 includes an air box18 upstream of engine 12 and containing a particulate filter forfiltering certain particulates from the intake airflow. Air box 18 isdisposed to one side of engine 12, being mounted on an interior panel ofa left front fender of the vehicle in the example of FIG. 1. Filteredair passes from an outlet of air box 18 through a conduit 20 to amanifold of engine 12 for distributing filtered air to the enginecombustion chambers.

Air box 18 also has an inlet through which unfiltered air, i.e. dirtyair, enters. Air is supplied to the air box inlet through a ductstructure 22 that is operatively associated with a D.C. storage battery24 of the vehicle's electrical system in accordance with principles ofthe present invention.

By itself, battery 24 is conventional, comprising a generallyrectangular casing having positive and negative posts 26, 28respectively via which it operatively connects with the electricalsystem. Battery 24 is typically a lead-acid storage battery that hassubstantial weight, and therefore supported in a secure, stable manneron weight-bearing structure of the vehicle, such as an underlyingbattery tray. Within engine compartment 10, battery 24 is exposed towhatever ambient temperature is present there. When engine 10 is hot,heat may also radiate toward battery 24, as portrayed by arrows 30.

By constructing and arranging duct structure 22 in accordance withprinciples of the invention, battery 24 may be protectively shielded atleast to some extent from engine compartment influences that tend toraise battery temperature. Accordingly, it is believed that theinvention provides a meaningful degree of beneficial battery cooling atelevated engine compartment temperatures.

Duct structure 22 is constructed from suitable polymeric material moldedby known molding methods to a formed shape for fitting into enginecompartment 10 in association with battery 24 in ways to be described.Duct structure 22 comprises a main air passageway 32 that runs from anintake 34 at one end, to an outlet 36 at an opposite end. Outlet 36 fitsto the air box inlet at a fluid-tight joint so that air entering intake34 passes freely through passageway 32 and into the interior of air box18. A section of the length of passageway 32 is disposed to runalongside a side wall 24A of the battery casing that is toward engine12. Where casing side wall 24A joins an end wall 24B of the casing,passageway 32 makes a right angle bend that extends about halfway alongend wall 24B. The passageway then makes an opposite right angle bend tothe air box inlet. The structure of passageway 32 that runs along casingside wall 24A and a portion of end wall 24B comprises inner and outerwalls 32A, 32B respectively of duct material, the inner and outer wallsbeing separated by the open interior of the passageway. Desirably thevertical dimension of passageway 32 equals or exceeds that of the casingside and end wall so that it covers the full height of the side of thecasing, but a passageway that is somewhat shorter may still be effectivefor the intended purpose.

When engine 12 is operating, intake airflow passes through passageway32, into air box 18 where it is filtered, and through conduit 20 intothe engine intake manifold.

Duct structure 22 provides a physical barrier to engine heat, bothradiant and convective, that would otherwise impinge directly on sideand end walls 24A, 24B of the battery casing. Some of that heat will beabsorbed by the duct structure material and dissipated to the intakeairflow through passageway 32, so that the thermal energy reachingbattery 24 is less than it would be in the absence of the protectiveeffect of passageway 32. It is therefore believed that the presence ofduct structure 22 can aid in limiting the rise of temperatures that tendto degrade leadacid storage batteries. For increasing efficiency, airinlet 34 should be situated at a location where the relatively coolestair can be drawn.

A further aspect of duct structure 22 relates to the inclusion ofbranches 38, 40 that are open to passageway 32, but otherwise closed,and that comprise additional inner and outer walls disposed in coveringrelation to those portions of the battery casing side and end walls notcovered by passageway 32. Branch 38 comprises a set of inner and outerwalls 38A, 38B disposed in covering relation to casing end wall 24C andan adjoining portion of casing side wall 24D. Branch 40 comprises a setof inner and outer walls 40A, 40B is disposed in covering relation to aportion of casing end wall 24B and an adjoining portion of casing sidewall 24D. Like passageway 32, each branch 38, 40 has a rectangulartransverse cross section, and preferably a height substantially equal tothat of the battery casing. Although branches 38, 40 are perhaps not asdirectly exposed to engine 12 as passageway 32 is, they are stillcapable of some contribution to thermal protection of battery 24.

Where each branch joins with passageway 32, it is open to thepassageway, but at its opposite end, it is closed. Hence, neither branchis capable of conducting throughflow. However, because each branchcomprises a closed volume that is open to passageway 32, it may beendowed with suitable features that enable it to also function as aresonator in the engine air intake system for performing a desiredtuning function appropriate to the particular engine. Specificconstructional details for any particular type of resonator desired tobe integrated in the inventive air intake and battery protection systemare known to designers of engine intake systems. One example of a dualresonator system is shown by FIG. 2 where branch 38 is constructed as aquarter-wave resonator and branch 40 as a Helmholtz resonator. Dependingon specific requirements for any given design, one or more resonatorsmay be integrated in a system, and the entirety, or only a fraction ofthe entirely, of the battery casing perimeter may be covered. Thus oneresonator 38 is covering one casing end wall, and the other resonator 40is covering the opposite end wall in FIG. 2, but the side wall facingaway from the engine is uncovered.

FIG. 3 discloses a further form of the invention, using like numbersfrom FIGS. 1 and 2 to designate like parts. Rather than having a singlepassageway 32 and resonators as in the embodiments of FIGS. 1 and 2, theduct structure 22 of FIG. 3 comprises a second passageway 44 that is inparallel flow relation to passageway 32. Passageway 32 may be considereda primary passageway and passageway 44, a secondary passageway. Bothpassageways have inner and outer walls and rectangular transverse crosssections for thermal shielding of battery 24. Battery 24 i disposed inan orientation 90° from its orientation in FIGS. 1 and 2, and passageway32 runs generally along casing end wall 24B and casing side wall 24D,while passageway 44 runs generally along casing side wall 24A and casingend wall 24C. Air box 18 comprises a rectangular filter 46 that is opento both passageways, facing in the general direction of casing side wall24D.

Where passageway 44 branches from passageway 32, the inner wall of thelatter is formed to have a deflector 48 that angles a short distanceinto the interior of passageway 32 immediately ahead of the entrance topassageway 44. Deflector 48 runs the full height of passageway 32 andserves to constrict passageway 32 immediately ahead of passageway 44. Itis believed that during low engine speeds, engine idle in particular,when the intake flow is relatively low and engine temperatures maybecome relatively high due to reduced coolant circulation through module14, the restrictive effect of deflector 48 causes an acceleration of theintake airflow that tends to maintain the intake airflow substantiallystraight through passageway 32 rather than allowing the flow to moreequally divide between the two passageways. However, at higher enginespeeds, the parallel passageways together provide a larger flow area forcollectively handling the increased flowrate. Hence, at low enginespeeds, the intake flow is forced to pass through that portion of theduct structure directly between the engine and the battery where it canbe most beneficial. This capability is imparted to the duct structurewithout use of moving parts to proportion flow through the passageways.And at higher engine speeds, the availability of parallel flow passagesprovides less restriction than just one of the passages. The primarypassageway 32 may be considered to comprise non-movable deflector wall48 disposed immediately upstream of the entrance of secondary passageway44. The arrangement is effective at a relatively lower flow rate toproportion the flow through the two passageways such that the proportionof flow through the primary passageway to the flow through the secondarypassageway is relatively larger than is the proportion of flow throughthe primary passageway to flow through the secondary passageway when theflow rate is relatively higher.

FIG. 4 discloses another form using like numbers from FIGS. 1-3 todesignate like parts. The single passageway 32 now runs along three ofthe four walls of the side of battery 24, as shown, with the fourth wall24C facing away directly away from engine 12.

FIGS. 5 and 6 disclose yet another form that possesses a battery fluidcontainment feature not present in any of the previous forms, althoughas will be appreciated, this containment feature may be embodied in anyof the previous forms. Should battery fluid escape the battery casingfor reasons such as spewing from a vent or a failure of the casing, itis desirable that the liquid electrolyte not entrain with the intakeairflow through passageway 32. Battery 24 is therefore housed within anenclosure 50 fabricated from acid-resistant material. Enclosure 50 isconstructed to have a generally rectangular shape just large enough forbattery 24 to fit inside. It has a generally horizontal top wallcovering the top of the battery casing and a vertical wall disposedaround the side and end walls of the battery casing, but is open at thebottom. Clearance space 52 is provided between the vertical enclosurewall and the battery.

Battery 24 is secured on a horizontal tray 54, also of acid-resistantmaterial. Tray 54 is perforated at certain locations so that fluidfalling on it can drain through perforations 53 to a sump 56 directlybeneath tray 54. Hence, if electrolyte escapes the battery casing, itwill be contained by enclosure 50 and drain by gravity into sump 56. Thefloor of sump 56 is sloped to a low point containing the entrance of aconduit 57 that carries the electrolyte to any suitable location whereit can drain by gravity onto the ground.

Where battery 24 rests on tray 54, the tray is corrugated so as toprovide a series of risers 59 separated by channels 61. The bottomsurface of battery 24 rests on the top surfaces of risers 59. Metalparts of battery hold-downs features are situated in locations whereescaped electrolyte will drain away from them.

To promote free drainage of liquid within enclosure 50, it is vented toatmosphere at or near its top by small open areas, or simply by suitableclearance 55 in the fit of its top wall to the top of battery 24. Noticethat the battery cap 58 is covered in such a way that spewed liquid willbe substantially contained on the top of the battery where it can spillover the edge and run down the side and or end walls of the casingthrough space 52.

Tray 54 comprises a short upright wall 60 that has a rectangular shapejust larger than the perimeter of the bottom edge of enclosure 50. FIG.6 shows that the installed enclosure fits to tray 54 in with the lowermarginal edge of the enclosure in closely telescopically overlappingrelationship to wall 60 such that such that a tortuous path that resistsescape of liquid between the two parts is created. This attachment-freefeature allows enclosure 50 to be conveniently installed and removedwhile providing satisfactory liquid containment.

Another advantageous feature of enclosure 50, as illustrated in FIG. 5,is its integration with the duct structure forming passageway 32. Thevertical side wall of enclosure 50 is shown to form inner wall 32A wherethe duct structure adjoins the enclosure. Also, the top wall and animmediately adjoining, downwardly extending portion of the outer wall32B of the duct structure are integrally formed with enclosure 50 wherethe duct structure adjoins the enclosure. The bottom wall and animmediately adjoining, upwardly extending portion of outer wall 32B areshown to be integrally formed with tray 54 where the duct structureadjoins enclosure 50. Thus a lower portion of the outer wall 32B isformed integrally with tray 54 and an upper portion, with enclosure 50,and when the enclosure is placed over the tray to enclose the battery,edges of the respective portions come together at a joint 63 thatmaintains substantial the integrity of the duct structure. The jointalong wall 60 also maintains substantial duct structure integrity.

Because of the telescopic fits in the joints between tray 54 andenclosure 50, they can be designed to accommodate industry-acceptedmanufacturer-to-manufacturer variations in battery casing dimensions.

Specific constructional details of any particular embodiment of thepresent invention are apt to depend to some extent on vehicle designfactors such as engine compartment size and placement of the battery inrelation to the engine. For example, passageway 32 and enclosure 50 mayshare a common wall. The inventive principles contemplate that certainfeatures of certain of the illustrated embodiments may be integratedwith certain features of other illustrated embodiments. Accordingly,while a presently preferred embodiment has been illustrated anddescribed, it is to be appreciated that the invention may be practicedin various forms within the scope of the following claims.

What is claimed is:
 1. In an engine compartment of an automotive vehicle that houses an internal combustion engine having an air intake system and that also contains an electrical system storage battery in spaced apart relation to the engine, the storage battery comprising a casing having an exterior containing positive and negative battery terminals via which the storage battery connects to an electrical system of the vehicle;duct structure that forms a portion of the air intake system and comprises an inlet at which intake air enters and a passageway that conveys the intake air from the inlet, lengthwise through the passageway, to an outlet; a portion of the length of the passageway being disposed in covering relation to an enclosure that associates with a tray on which the battery casing is supported to enclose the battery casing; the enclosure comprising a top that covers a top of the battery casing and a perimeter wall extending downward from the top to the tray in covering relation to the perimeter of the battery casing.
 2. In an engine compartment as set forth in claim 1, the tray comprising an upright perimeter wall with which a bottom edge margin of the perimeter wall of the enclosure has a snug telescopic fit.
 3. In an engine compartment as set forth in claim 1, the enclosure comprising an atmospheric vent that allows free drainage of liquid within the enclosure, and the tray comprising perforations providing for liquid to drain through the tray.
 4. In an engine compartment as set forth in claim 1, the tray and the enclosure comprising respective wall portions that come together at a joint to cooperatively form the portion of the passageway that is disposed in covering relation to the enclosure.
 5. In an engine compartment as set forth in claim 4, the tray and the enclosure comprising respective wall portions that are constructed and arranged to accommodate industry-accepted manufacturer-to-manufacturer variations in battery casing dimensions.
 6. In an engine compartment as set forth in claim 1, a portion of the length of the passageway being disposed in covering relation to a wall of the battery enclosure that is toward the engine; and the duct structure further comprising a branch that is disposed in covering relation to another wall of the battery enclosure and that comprises a space that is open to the passageway, but otherwise closed.
 7. In an engine compartment as set forth in claim 6, the duct structure comprising another branch that is disposed in covering relation to a further wall of the battery enclosure and that comprises a space that is open to the passageway, but otherwise closed.
 8. In an engine compartment as set forth in claim 7, at least one of the branches being constructed and arranged to form a resonator for tuning the air intake system to operation of the engine.
 9. In an engine compartment as set forth in claim 8, both of the branches being constructed and arranged to form respective diverse resonators, each for tuning the air intake system in a manner diverse from the other to operation of the engine.
 10. In an engine compartment as set forth in claim 7, one branch being open to the passageway upstream of a location where the other branch is open to the passageway, and collectively, the passageway and the branches being in covering relation to an entire perimeter that comprises the walls.
 11. In an engine compartment as set forth in claim 1, the duct structure further comprising a secondary passageway that is disposed in covering relation to another wall of the battery enclosure and that branches from the first-mentioned passageway, comprising an entrance upstream of the portion of the length of the first-mentioned passageway that is disposed in covering relation to a wall of the battery enclosure that is toward the engine and an exit downstream of the portion of the length of the primary passageway that is disposed in covering relation to a wall of the battery enclosure that is toward the engine; and in which the first-mentioned passageway comprises a non-movable deflector wall that is disposed immediately upstream of the entrance of the secondary passageway and is effective at a relatively lower flow rate to proportion the flow through the two passageways such that the proportion of flow through the first-mentioned passageway to the flow through the secondary passageway is relatively larger than is the proportion of flow through the first-mentioned passageway to flow through the secondary passageway when the flow rate is relatively higher.
 12. In an engine compartment as set forth in claim 1, the storage battery comprising a battery cap on the casing, and a portion of the enclosure being disposed in covering relation to the battery cap.
 13. In an engine compartment as set forth in claim 12, the battery cap being disposed on the top of the casing, and the portion of the enclosure disposed in covering relation to the battery cap being a portion of the top of the enclosure.
 14. In an engine compartment as set forth in claim 13, the atmospheric vent being provided in the top of the enclosure by an open clearance in the enclosure top relative to the battery casing.
 15. In an engine compartment as set forth in claim 3, the atmospheric vent being provided in the top of the enclosure by an open clearance in the enclosure top relative to the battery casing.
 16. In an engine compartment as set forth in claim 3, further including a sump which is disposed in underlying relation to the tray and into which liquid that has passed through the perforations drains.
 17. In an engine compartment of an automotive vehicle that houses an internal combustion engine having an air intake system and that also contains an electrical system storage battery in spaced apart relation to the engine;duct structure that forms a portion of the air intake system and comprises an inlet at which intake air enters and a passageway that conveys the intake air from the inlet, lengthwise through the passageway, to an outlet; a portion of the length of the passageway being disposed in covering relation to an enclosure that associates with a tray on which the battery is supported to enclose the battery; the enclosure comprising a top that covers a top of the battery and a perimeter wall extending downward from the top to the tray in covering relation to the perimeter of the battery; the enclosure comprising an atmospheric vent that allows free drainage of liquid within the enclosure; and the tray comprising perforations providing for liquid to drain through the tray into a sump below the tray. 